Rare earth aluminates and gallates supported rhodium catalysts for catalytic partial oxidation of hydrocarbons

Abstract

The present invention relates to improved catalyst compositions, as well as methods of making and using such compositions. In particular, preferred embodiments of the present invention comprise rare earth catalyst supports, catalyst compositions having rare earth supports, and methods of preparing and using the catalysts and supports. Accordingly, the present invention also encompasses an improved method for converting a hydrocarbon containing gas and an oxygen containing gas to a gas mixture comprising hydrogen and carbon monoxide, i.e., syngas, using the rare earth catalyst supports in accordance with the present invention. In addition, the present invention contemplates an improved method for converting hydrocarbon gas to liquid hydrocarbons using the novel syngas catalyst supports and compositions described herein.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]Not applicable.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT[0002]Not applicable.FIELD OF THE INVENTION[0003]The present invention generally relates to catalysts and processes for the catalytic conversion of hydrocarbons (e.g., natural gas) using rare earth based catalysts to produce carbon monoxide and hydrogen (synthesis gas). More particularly, the invention relates to such catalysts and their manner of making, and to processes employing the catalysts for production of synthesis gas.BACKGROUND OF THE INVENTION[0004]Catalysis is the basis for many industrial / commercial processes in the world today. The most important aspect of a catalyst is that it can increase the productivity, efficiency and profitability of the overall process by enhancing the speed, activity and / or selectivity of a given reaction. Many industrial / commercial processes involve reactions that are simply too slow and / or efficient to be economical witho...

AI Technical Summary

Benefits of technology

[0015]The present invention is directed towards improved catalyst compositions, as well as methods of making and using such compositions. In particular, preferred embodiments of the present invention comprise rare earth catalyst supports, catalyst compositions having rare earth supports, and methods of preparing and using the catalysts and supports. Accordingly, the present invention also encompasses an improved method

Problems solved by technology

Many industrial / commercial processes involve reactions that are simply too slow and / or efficient to be economical without a catalyst present.

After a period of time in operation, a catalyst will become deactivated, losing its effectiveness for enhancing the desired reaction to a degree that makes it uneconomical at best and inoperative at worst.

However, replacing a catalyst typically means discarding the deactivated catalyst.

A discarded catalyst represents a loss of expensive metals.

However, the recovery process involves dissolving the multi-component catalyst and subsequent separation of the active components from the mixed solution.

The chemistry is complex and costly, more importantly, it involves bulk amounts of harsh chemicals that ultimately must be discarded and the use of landfills for such disposal is problematic.

Most of these processes are reversible, although not economically feasible.

Further, the coke results in an increase in pressure drop across the catalyst bed due to the buildup of carbon in the flow paths or interstices.

Sintering is particularly difficult to regenerate and has traditionally been viewed as a non-reversible phenomenon.

Because regeneration has traditionally been so difficult, the catalytic metals are typically dissolved and recaptured for use in new catalyst batches.

At the present time, there are no known methods that are economically feasible for regenerating a sintered syngas catalyst.

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